Hybrid part manufacturing system and method

ABSTRACT

A system and method for manufacturing a part in a mold having a mold cavity including a printhead for depositing a first material within the mold cavity, and an injection head for depositing a second material within the mold cavity. A part can be made in the mold cavity by the cooperative use of both injection molding and additive manufacturing steps.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of U.S. application Ser. No. 15/043,965,filed on Feb. 15, 2016, now U.S. Pat. No. 10,179,430, issued Jan. 15,2019, titled “HYBRID PART MANUFACTURING SYSTEM AND METHOD”, which ishereby expressly incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates to a manufacturing systemand method with both injection molding and additive (3-D printing)features. Injection molding and various techniques therefor have becomeubiquitous in the manufacturing sector. Recently, “additive”manufacturing techniques, also referred to as “3-D printing” have comeinto favor, typically in the rapid prototyping stage of productdevelopment. A challenge with injection molding and additivemanufacturing processes is maintaining uniform temperatures during thepart-manufacturing process. This constraint can limit the size andproduction rate of components that can be made by these processes. Bothtechniques can also be constrained in the way that parts can be orientedduring manufacturing and the kinds of features (e.g., undercuts, thinstructures) that can be fabricated using these techniques.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, aspects of the present disclosure relate to a hybrid partmanufacturing system. In one embodiment, a mold can have a set ofmovable mold portions, wherein, in a first molding position, the set ofmold portions can cooperate to define an injectable mold cavity, andwherein, in a second additive manufacturing position, the set of moldportions can be repositioned to define an access area for additivemanufacturing operations to be performed on a part formed inside theinjectable mold cavity.

In another aspect, aspects of the present disclosure relate to a methodfor manufacturing a part in a mold, wherein the mold includes a moldcavity, including the steps of: providing a source of injectablematerial; providing a source of printable material; closing the mold toform a closed mold cavity; forming a portion of a part within the moldcavity with a first volume of the injectable material; opening at leasta portion of the mold to allow access to the portion of the part formedin the mold cavity; printing a second volume of the printable materialonto the portion of the part formed in the mold cavity to form anadditional portion of the part; and removing the formed part from themold.

In another aspect, aspects of the present disclosure relate to a systemfor making a part including: a mold having a mold cavity; a printheadfor depositing a first material within the mold cavity; an injectionhead for depositing a second material within the mold cavity; wherein apart is formed by the cooperative deposition of the first material bythe printhead and the second material by the injection head.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a flow chart illustrating an exemplary method ofmanufacturing a part in a mold;

FIG. 2 illustrates a step for producing part a using injection moldingand additive manufacturing methods from one or more of the steps of FIG.1 in greater detail;

FIG. 3 is a schematic side elevational view of a system formanufacturing a part using molding and additive manufacturing techniquesshown with respect to the methods described with respect to FIGS. 1-2;

FIG. 4 is a side elevational view of the schematic shown in FIG. 3showing greater detail on the molding and additive manufacturingcomponents;

FIG. 5 is an end elevational view of the schematic shown in FIG. 4;

FIG. 6 is a device for providing injectable and printable material forthe system shown in FIGS. 3-5 and according to the methods describedwith respect to FIGS. 1-2;

FIG. 7 is a device for providing injectable and printable material inaccordance with various aspects described herein;

FIG. 8 is a device for providing injectable and printable material inaccordance with various aspects described herein;

FIG. 9 is an example configuration illustrating the system shown inFIGS. 3-5 and the methods described in FIGS. 1-2 in which a fabricmaterial is suspended on retainers located within a mold cavity;

FIG. 10 is an example configuration illustrating the system shown inFIGS. 3-5 and the methods described in FIGS. 1-2 in which a fabricmaterial is suspended on retainers located within a mold cavity inaccordance with various aspects described herein;

FIG. 11 is an example configuration of a mold according to FIGS. 3-5 andthe methods described with respect to FIGS. 1-2 in which a fabricmaterial is suspended with respect to a portion of the mold to enable afabric material to be provided as a laminar component within a partbeing manufactured;

FIG. 12 illustrates an exemplary finished product having a fastenersuspended within layers of polymeric material and reinforced fabricmaterial from the mold configuration shown in FIG. 11; and

FIG. 13 illustrates the exemplary finished product of FIG. 12 having anadditional additive manufacturing component provided thereto afterinjection molding operations formed the part as shown in FIG. 12.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Turning now to the drawings and to FIG. 1 in particular, a method 10 isillustrated for forming parts in a mold by using both injection-typemanufacturing methods and additive manufacturing methods, which can alsobe referred to as 3-D printing methods, according to aspects of thepresent disclosure. The term “hybrid” is used herein to refer to theability of the system and method described herein to permit themanufacture of a part in a mold using both injection molding andadditive manufacturing techniques.

In the method 10 of FIG. 1, the method 10 begins with step 12 in whichthe part is designed using typical CAD/CAM manufacturing and designmethods. Once the part is designed in step 12, a suitable mold can befabricated, typically with heating elements provided in the mold toensure uniform heating of the mold and the part material at step 14.Optionally, at step 16, a coating can be added to the mold cavity withinthe mold to facilitate part removal when the mold is opened to removethe formed part therefrom.

The terms “mold” and “mold cavity” are used as would be understood byone skilled in the art to which aspects of the present disclosurepertains. Various examples of a mold and mold cavity are discussedherein, and the particular examples discussed should not be construed asbeing limiting on the scope of the present disclosure. In general, amold as described herein need only describe or define a mold cavity inwhich the part can be molded. In various examples, the mold can have aset of movable mold portions. It will be understood that “a set” caninclude any number of the respectively described elements, includingonly one element. The mold portions can be movable between a firstposition and a second position. The first position can be considered afirst molding position in which the set of mold portions can cooperateto define an injectable mold cavity in which a part can be formed byinjection molding techniques. The second position can be considered asecond additive manufacturing position, in which the set of moldportions can be repositioned to define an access area for additivemanufacturing operations to be performed on the part being formed in themold cavity.

The terms “injectable material” is used generally herein to refer to anysuitable material used in molding operations, and injection moldingoperations in particular, although any particular material can be usedwithout departing from the scope of aspects of the present disclosure.The term “printable material” is used generally herein to refer to anysuitable material used for additive manufacturing operations. Theinjectable material and printable material can be the same material ordifferent materials. If different materials are used they can becomplementary materials that can form an integral relationship when usedin a common part.

At step 18, part formation and manufacturing processing parameters canbe set on the particular mold equipment that is used to control andoperate the mold, such as a build sequence for the mold and materialaddition method, and rates that the material is to be added to theprocess. At step 18, the mold parameters and processing parameters caninclude a decision in which particular portions of the part being formedcan be formed by adding material using injection molding techniques and,in other steps of the build sequence for the part being formed in themold at step 18, portions of the part being formed can be made byadditive manufacturing techniques.

At step 28, it is determined whether the build sequence determined instep 18 produces optimized part cooling. If so, processing moves to step22 in which production runs of the part formed in the mold can be madeusing the build sequence set in step 18 to form the part using injectionmolding and additive manufacturing techniques. If the decision point at20 does not result in an optimized part cooling parameter for the partbeing formed in the mold, processing can return to step 18 to insertdifferent parameters in the build sequence for forming the part in themold.

After step 22, processing can move to step 24 in which finishingoperations can be performed on the part being formed in the mold withinthe mold cavity. At step 26, the formed part is removed from the mold.

It will be understood that injection molding techniques and otherreferences to injection molding are referred to generally as anymanufacturing process in which flowable material is provided into a moldcavity, including, but not limited to, high-pressure and low-pressureinjection molding techniques. It will also be understood that additivemanufacturing techniques are referred generally herein to amanufacturing process in which certain features of a formed part areadded step-wise by repetitively printing small portions of the part froma print head. For example, a part can be formed in a mold by using bothinjection-molding techniques as well as additive manufacturingtechniques in the same molding operation.

Turning to FIG. 2, step 22, which was shown in FIG. 1, refers toproducing a part in a mold cavity using injection molding and additivemanufacturing methods and is shown in greater detail. For example, atstep 28, a mold for a specified part is installed in a molding device.At 30, a decision is made as to whether the part to be formed in themold includes any sort of fabric layer or portion formed from carbonfiber or a woven material, often referred to as a structural wovenmaterial. If the part does not include this type of material, processingmoves to 32 in which the mold is filled using injection moldingtechniques and additional features of the part are formed by additivemanufacturing techniques as shown in step 32.

If, at step 30, it is determined that the part does include some sort ofwoven material or carbon fibers, processing moves to step 34 in whichone or more fabric layers are aligned within the mold cavity and canoptionally detention and on provided anchors located within portions ofthe mold in the mold cavity.

At step 36, the carbon fiber or structural material is pulled along themold profile using the anchors to locate the carbon fiber or wovenmaterial within the mold cavity. At 38, the mold is closed and thematerial is tensioned to a final desired parameter. Once the carbonfiber or structural woven material is located within the mold cavity asdescribed in steps 34-38, processing returns to step 32 in which themold cavity is filled using injection holding and additive manufacturingtechniques to produce a part including the located carbon fiber orstructural woven material.

Turning to FIG. 3, an example system for manufacturing a part in a moldusing the hybrid injection molding and additive manufacturing techniquesdescribed herein with respect to aspects of the present disclosure,including those described by example in FIGS. 1-2, is generallydescribed with reference numeral 40. It will be understood by oneskilled in the art that FIG. 3 illustrates the system 40 schematically.The components described in FIG. 3 would be apparent to one skilled inthe art.

The system 40 includes a mold shown generally by reference 42, and a setof material dispensers 44 movably positioned with respect to the mold42. The material dispensers 44 are interconnected with a source 46 ofmaterial for making at least portions of a part in the mold 42. It willbe understood that the source 46 of material for the part can include asource of injectable material, a source of printable material, or both.Furthermore, the source 46 can provide additional sources of materialother than the two classes of materials mentioned herein. In addition,the material dispensers 44 are shown interconnected to the source 46 bysupply lines 48. The material dispensers 44 are shown interconnected tocontroller(s) 50 by a suitable communication connection 52, as shown inFIG. 3. With this configuration, the controller(s) 50, via theconnection 52, can control the position of the material dispensers 44,preferably over multiple axes of movement and rotation. The materialdispensers 44 can be provided with injectable material or printablematerial, or both, through the supply lines 48 from the source ofmaterial 46. The number of material dispensers 44 can be selected for agiven part production application, multiple material dispensers 44 canbe employed to increase part production rates, match fill times, and topromote uniform cooling.

As also shown in FIG. 3, the mold 42 can be any suitable moldingequipment, including, but not limited to, a mold for creating a partusing flowable material (such as material typically used in high- orlow-pressure injection molding operations, which would be apparent toone skilled in the art). In the example embodiment shown in FIG. 3, themold 42 includes a base platform 54 with a set of mold portions 56,which cooperate to define a mold cavity 58 in which a part can bemanufactured. It will be understood that the mold portions 56 can bemovable about at least one axis, and preferably three axes of linearmovement and at least one axis of rotational movement, with respect tothe base platform 54 so that the mold cavity 58 can be positioned into afirst molding position in which flowable or injectable material can beprovided from the source 46 through the supply lines 48 and to thematerial dispensers 44 for dispensation into the mold cavity 58 to format least a portion of a part within the mold cavity 58 as defined by adesired shape of the mold cavity, typically with a tooling elementplaced therein. As shown by the arrows above the set of mold portions56, the mold portions can be movable with respect to the mold cavity 58to position the mold cavity 58 into a first molding position wherein themold cavity is preferably enclosed for injection molding operations, anda second open or additive manufacturing position. In the secondposition, the mold 42 and, in particular, the mold cavity 58, can beaccessible by the material dispensers 44 to provide additivemanufacturing operations on the portion of a part formed by injectionmolding operations within the mold cavity 58. The material dispensers 44can be movable so as to be positionable within the mold cavity 58.Further, control logic can be provided to the material dispensers 44 bythe controllers 50 to prevent each material dispenser 44 from cominginto a motion path of another material dispenser 44 as well as toprevent material dispensed by the material dispensers 44 from impingingon another material dispenser. It would be apparent to one skilled inthe art that material dispensed by the material dispensers 44 can be inany direction therefrom, toward or away from the mold portions 50,although it would also be apparent to one skilled in the art that it canbe preferred to inject material toward the mold portions 50 becausein-mold material cannot be depended upon to flow toward boundary areasof the mold cavity 58.

FIG. 4 shows an example of the system 40, introduced with respect toFIG. 3, in greater detail. Common components shown in FIG. 3 anddiscussed with respect to FIG. 4 are described with, and referenced,with common reference numerals, and their description is not repeated.In the example shown in FIG. 4, the set of mold portions 56 are shownhaving an actuator 60, which is configured to provide lateral movementto a corresponding mold portion 56 to allow the mold portion 56 to bemoved between the first and second positions for the mold 42. Optionalheating channels 62 are illustrated as being provided in the moldingportions 56 and the base platform 54. The movement of the mold portion56 is illustrated by the arrows positioned adjacent to the actuator(s)60. In this way, the size and accessibility of the mold cavity 58 can beadjusted in accordance with the build process set in the method 10described with respect to FIGS. 1-2.

In FIG. 4, the system 40 is shown enclosed within a housing 64 this canprovide the material dispenser 44 an environment within which to operateand perform both injection molding and additive manufacturing operationson a part being formed in the mold cavity 58. An optional imagingsystem, such as a camera shown by reference numeral 66, can be providedassociated with the housing 64 to allow for imaging to be performed onthe manufacturing operations performed within the housing 64 and toprovide feedback to a controller 50 provided for the material dispenser44. Further, the camera 66, if it has infrared detection capabilities,could be used to provide feedback to one or more controllers 50 forcontrolling heating elements in the mold 42 and to assess cooling of thepart being formed, as well as readiness for the next stages ofoperations to be performed on a part in the mold cavity 58. The camera66 can be any known type, including visual and infrared. While a singlecamera 66 located in an upper center area of the housing 64 is shown inFIG. 4, it would be apparent to one skilled in the art that the numberof cameras 66 could be increased without departing from the scope ofthis invention. Furthermore, the position of the cameras 66 could belocated anywhere associated on or within the housing 64 withoutdeparting from the scope of the invention.

FIG. 5 is an end view of the embodiment of the system 40 shown in FIG.4. As would be understood by one skilled in the art, the system 40contemplates the use of one, or more than one, material dispenser 44interconnected with a source 46 of injectable or printable material anda controller 50 for positioning the material dispenser 44 within thehousing 64. With the multiple material dispensers 44 shown in theexample of FIG. 5, it will be understood that multiple materialdispensers could be sealingly interfaced with the mold cavity 58 toprovide injectable material at multiple locations for injection moldingoperations within the mold cavity 58. In addition, because the materialdispensers 44 can also have a printhead provided thereon, it would bewithin the scope of the present disclosure for the material dispensers44 within the housing 64 to provide additive manufacturing techniques ona part being formed in the mold cavity 58 at different locationsthereof.

In addition, it is also within the scope of the present disclosure, andwould be apparent to one skilled in the art, that one material dispenser44 could have an injection molding nozzle provided thereon for injectinga source of injectable material from the source 46 into the mold cavity58 and another material dispenser 44 provided within the housing 64could have a printhead provided thereon and be interconnected to asource 46 of printable material. In this example embodiment, onematerial dispenser 44 could provide injectable material during aninjection molding operation within the mold cavity 58 and then anothermaterial dispenser 44 could then perform additive manufacturingoperations by dispensing printable material from a source 46 ofprintable material after portions of the part have been formed byinjection molding.

As shown in FIGS. 4-5, the material dispenser 44 is shown on an arm 68which can be articulated, preferably in three axes and at least aboutone axis of rotation, throughout the housing 64 to reposition thematerial dispenser 44 in any number of locations within the housing 64with respect to the mold cavity 58. It will be understood that theparticular configuration of the arm 68 can be any form of a robotic,mechanical or electromechanical device and would not be limiting on thescope of the present disclosure with respect to the particularimplementation of the arm 68 used to move the material dispenser 44associated with the arm 68 within the housing 64.

FIGS. 6-8 illustrate various embodiments of the material dispenser 44 asshown by example in FIGS. 4-5. It will be understood that theillustrations of FIGS. 6-8 are by example only, and are provided toillustrate the flexibility and adaptability of the material dispenser 44according to aspects of the present disclosure, but should not beconstrued as limiting upon the scope of the present disclosure. In FIGS.6-8, the material dispenser 44 is shown on a portion of the arm 68 forarticulating and positioning the material dispenser 44 within thehousing 64 described with respect to FIGS. 4-5 but not shown in theenlarged inset orientations of FIGS. 6-8. In the exemplary illustrationsshown in FIGS. 6-8, a radiative heater (not shown for brevity) can beprovided on the arm 68 or on the material dispenser 44 itself to providecontrollable heat to the injection and additive manufacturing operationspursuant to the system 40 and method 10 described herein.

Turning to FIG. 6, an embodiment of the material dispenser 44 is shownhaving both a nozzle 70 positioned adjacent an end of the arm 68 and aprinthead 72, preferably positioned adjacent to the nozzle 70. Thenozzle 70 is shown interconnected to a source 46 of injectable material74 by a supply line 48. It will be understood by one skilled in the artthat the injectable material can be provided in a fluid form, or a solidform, such as a pellet or filament feed, and melted during the injectionprocess. The printhead 72 is shown interconnected to a source 46 ofprintable material 76, which is typically provided in a filament or wireform, and extends through a supply line 48 to the printhead 72. It willbe understood that both the nozzle 70 for injecting the injectablematerial 74 and the printhead 72 for performing additive manufacturingoperations with the printable material 76 can be any number of suitableconfigurations which would be apparent to one skilled in the art. It isa feature of aspects of the present disclosure that the injectablenozzle 70 and the printhead 72 are carried on a common element, such asarm 68, so that these elements can be moved as a unit for performingmolding operations using injectable material 74 and additivemanufacturing operations using printable material 76 at variouslocations with respect to the mold cavity 58 (not shown in the insetorientation of FIG. 6).

FIG. 7 shows an alternative embodiment of the material dispenser 44, inwhich a source 46 of injectable material 74 is connected via a supplyline 48 to a switching device 80. A source 46 of printable material 76is connected via a supply line 48 to the switching device 80 as well.The switching device 80 is shown in a schematic or diagrammatic form inthe example embodiment of FIG. 7 and can be any device which can bemechanically or electronically switched so that the output of theswitching device 80 is provided to a combined nozzle 78 adjacent an endof the arm 68. In this manner, injection molding operations can beprovided by setting the switching device 80 to fluidly interconnect thesource 46 of injectable material 74 via the supply line 48, through theswitching device 80, to the combined nozzle 78 which will dispenseinjectable material through the combined nozzle 78 to the mold cavity 58as positioned by the arm 68. Alternatively, when the switching device 80is set to an opposite mode, printable material 76 is provided via asupply line 48 to the switching device 80 so that the printable materialis provided to the combined nozzle 78 so that additive manufacturingoperations can be performed on a part formed in the mold cavity 58 aspositioned by the arm 68. The combined nozzle 78 and switching device 80can allow for the material dispenser to be provided in a smallerfootprint.

FIG. 8 illustrates that the material dispenser 44 can be positionedadjacent to an end of the arm 68 wherein the combined nozzle 78 is shownin greater detail including an optional heat shield 82 with an adjacentinjection nozzle 70 and a printhead 72 positioned adjacent in end of thearm 68. The heat shield 82 is preferably positioned between the arm 68and the injection nozzle 70 and the printhead 72. A source 46 ofinjectable material 74 can be provided via a supply line 48 to theinjection nozzle 70 through the heat shield 82. Alternatively, a source46 printable material 76 can be provided via a supply line 48 to theprinthead 72 through the heat shield 82. In this manner, the arm 68 canpositioned the material dispenser 44 with respect to the mold cavity 58so that injection molding operations can be performed by passinginjectable material 74 through the supply line 48 to the nozzle 70 sothat portions of a part can be formed in the mold cavity 58 by injectingmaterial from the nozzle 70. Alternatively, additive manufacturingoperations can be performed on the part in the mold cavity 58 by passingprintable material 76 via the supply line 48 to the printhead 72 asdescribed with respect to the other embodiments of FIGS. 6-8.

FIGS. 9-10 show a portion of the system 40 described with respect toFIGS. 3-5 in which fabric, such as a carbon fiber material or astructural woven material, can be located within the mold cavity 58. Itwill be understood that, components in FIGS. 9-10 that are common withrespect to the embodiments of the system 40 described with respect toFIGS. 3-5 are described with like reference numerals and are notdescribed again with respect to FIGS. 9-10.

In the example shown in FIG. 9, a portion of fabric 84 is tensionedacross the mold cavity 58 by the provision of hooks 86 within the moldcavity 58 by attachment of the hooks 86 to desired mold portions 56 asshown by example in FIG. 9. In the example shown in FIG. 9, two layersof fabric 84 are shown extending generally horizontally across the moldcavity 58. It would be apparent to one skilled in the art thatadditional or fewer pieces of fabric 84 can be provided within the moldcavity, and in any desired direction, orientation or volume, withoutdeparting from the scope of the present disclosure. As would be apparentto one skilled in the art, the position, location, and size, and type ofthe fabric 84 would be dictated by the specifics of the part beingformed, and the specifics of which should not be construed as beinglimiting on the scope of the present disclosure.

Once the fabric 84 is positioned across the mold cavity 58 on the hooks86 in the example of FIG. 9, the manufacturing steps of injectingmaterial into the mold cavity 58 and performing additive manufacturingoperations to provide additional material to the part being formed inmold cavity 58 can be performed as described with respect to otheraspects of the present disclosure described herein.

Turning to FIG. 10, another example of providing a length of fabric 84within the mold cavity 58 is shown. In this example, several hooks 86are provided on a set of the mold portions 56 as well as on the baseplatform 54. A tensioning device 88 can be provided in a desiredposition associated with the mold cavity 58, but preferably outsidethereof, to provide tension to the fabric 84 as it is provided in a partbeing formed in the mold cavity 58. As described with respect to otherembodiments of the system 40, once the fabric 84 is positioned withinthe mold cavity 58, the manufacturing operations, including theinjection of injectable material and additional additive manufacturingoperations including the provision of printable material on a part beingformed in the mold cavity 58 can be performed to integrate the fabric 84into the part being formed in the mold cavity 58. As would be apparentto one skilled in the art, the fabric 84 is shown in the embodiment ofFIG. 10 as being an endless length of fabric 84, such as would typicallybe provided on a roll or spool of material, and provided tensioning bythe device 88. Then, once the material has been injected in/or addedaround the fabric 84 as would be apparent to one skilled in the art, theany remaining fabric 84 not included in the part being formed in themold cavity 58 can be severed, the part removed from the mold cavity 58,and the next successive length of fabric 84 extended into the moldcavity 58 for subsequent molding and additive manufacturing operations.

FIG. 11 shows enlarged inset portion of a pair of mold portions 56 in anexample embodiment of the system 40 described herein. In the exampleshown in FIG. 11, a sleeve 90 is positioned between a pair of adjacentmold sections 56 and a pair of polymeric threaded fasteners 92 arethreaded into the sleeve 90. A washer 94 can optionally be providedbetween the threaded fasteners 92 as required by a particular operation.The function of the threaded fasteners 92 and its engagement with thesleeve 90 and an optional washer 94 is to retain a portion of the fabric84 in place during molding operations within the mold cavity 58. Aclamping device 96 can be provided associated with the portion of themold 42, such as the base platform 54, to hold a length of the fabric 84in place. In order to configure the molding operation for the hybridmanufacturing techniques described herein, a length of the fabric 84 isretained between a threaded fasteners 92 and the sleeve 90 and anoptional washer 94 within the mold cavity 58. Then, injection moldingtechniques and additive manufacturing techniques are performed withinthe mold cavity 58 which thereby surround the threaded fasteners 92 andthe fabric 84 retained between the threaded fasteners 92 and the sleeve90 and the optional washer 94. Other post-manufacturing finishingoperations can be performed by additive manufacturing techniques on thesurface of the part formed in the mold cavity, as well as otherfinishing operations which would be apparent to one skilled in the art.

FIG. 12 shows layers of material 98 surrounding a layer of fabric 84after injection molding operations have been performed in the moldcavity 58. An aperture left by the removal of the threaded fastener 92can be filled by additive manufacturing techniques, according to aspectsof the present disclosure, to fill the aperture with material as shownin FIG. 12. An example additive component 100 is shown in FIG. 13, whichis a view similar to that of FIG. 12, but with an opening filled withthe post-injection-operation additive component 100.

Once the manufacturing operations described herein are completed on apart being formed in the mold cavity 58, the mold 42 can be positionedin an open position to allow the part to be removed, or ejected, fromthe mold 42. It will be understood by one skilled in the art that, tothe extent a stacked multiple-part mold is employed, such as one shownby example in the embodiments herein, alternating motion can be impartedto the mold portions 56 between adjacent layers of the mold stack toassist in releasing the part from the mold 42. In addition, pulsatingthermal loads can be provided to the mold portions 56 to assist inreleasing the part from the mold 42.

The hybrid manufacturing system 40 and method 10 described hereinprovides a variety of benefits including that they combine desirablefeatures of both injection molding and additive manufacturing techniquesallows for rapid part construction using any additive build material(epoxies, plastics, etc.) as well as combining bulk material flow, layerbuilding, molds, and detailed additive manufacturing. The system andmethod described herein can consist of multiple material dispensingheads and a mold that defines an accessible mold cavity. In some exampleembodiments described herein, the material dispensing heads can allowfor multiple speeds of liquid flow into the mold cavity through a heatednozzle with a controllable flow cross-section (such as with, forexample, a screw-actuated valve). The nozzle can switch modes to printdetail above and beyond the limits of the mold using additivemanufacturing techniques. In another example, the mold itself can besectioned and actuated to account for complex geometries of parts beingproduced. The nozzle can also potentially be outfitted with thermalradiation heaters in order to maximize uniformity of temperature betweenmold, print head, and cooling additive material.

The system 40 and method 10 described herein can handle the manufactureof very long, narrow plastic parts that ordinarily require extremelyhigh pressures and normally would preclude the use of undercuts orcomplicated geometries because conventional injection molding techniqueswould require multiple injection points or risk intrinsic thermalstresses. By using a movable injection nozzle such as that describedhere that can fill a mold as well as print material into or onto themolded part, complex geometry parts can be built in dimensions largerthan conventional additive manufacturing processes and at faster speeds.Potential applications could be wind turbine blades or engine turbineblades. Inclusion of carbon fiber within the mold inside a frame wouldallow rapid carbon-fiber part generation using an automated process.

In the context of additive manufacturing, the system and methoddescribed herein allows for faster part development for large volumeparts requiring elements such as solid cross sections and detailedfeatures. In the injection molded part technology area, the system andmethod described herein solves issues associated with very large or longparts which require high injection pressures, multiple plastic gatepoints, and would suffer from cracking due to thermal stresses intrinsicin large parts which could have non-uniform cooling within the mold whenconventional manufacturing techniques would be used.

To the extent not already described, the different features andstructures of the various embodiments may be used in combination witheach other as desired. That one feature may not be illustrated in all ofthe embodiments is not meant to be construed that it may not be, but isdone for brevity of description. Thus, the various features of thedifferent embodiments may be mixed and matched as desired to form newembodiments, whether or not the new embodiments are expressly described.All combinations or permutations of features described herein arecovered by this disclosure.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

What is claimed is:
 1. A method for manufacturing a part in a mold,comprising: providing a source of injectable material; providing asource of printable material; closing a mold, having a mold cavity, toform a closed mold cavity; forming a portion of a part within the moldcavity with a first volume of the injectable material; opening at leasta portion of the mold to allow access to the portion of the part formedin the mold cavity; printing a second volume of the printable materialby additive manufacturing onto the portion of the part formed in themold cavity to form an additional portion of the part; and removing thepart from the mold.
 2. The method of claim 1, further comprising thestep of providing an injection nozzle fluidly interconnected to thesource of injectable material and movably positioned with respect to themold cavity.
 3. The method of claim 2, further comprising the step ofproviding a printhead fluidly interconnected to the source of printablematerial and movably positioned with respect to the mold cavity.
 4. Themethod of claim 1, further comprising the step of providing the mold asa series of stacked, movable mold portions which are jointly movable toform the mold cavity in a first mold position, and at least one of themold portions are movable to form an access point to the mold cavity ina second mold position.
 5. The method of claim 1, further comprising thestep of locating a fabric material within the mold cavity prior to thestep of forming the portion of the part within the mold cavity with afirst volume of the injectable material.
 6. The method of claim 5wherein the fabric material includes carbon fiber material.
 7. Themethod of claim 1 further comprising a step of printing an initialvolume of the printable material in the mold cavity prior to the step offorming the portion of the part within the mold cavity with the firstvolume of the injectable material, wherein the initial volume of theprintable material and the first volume of the injectable material format least a portion of the part formed in the mold cavity.
 8. The methodof claim 1, further comprising the step of forming heating elements intothe mold around at least a portion of the mold cavity.
 9. The method ofclaim 1, wherein providing a source of printable material comprisesproviding the additive build material in the form of a filament or wire.10. A method for manufacturing a part in a mold, comprising: forming amold cavity in the mold with at least one mold portion; injecting aninjectable material by injection molding into the mold cavity to form afirst volume of the part; printing an additive build material byadditive manufacturing onto the first volume to form an additionalvolume of the part; and removing the part from the mold.
 11. The methodof claim 10, further comprising articulating an arm carrying a materialdispenser to reposition the material dispenser.
 12. The method of claim11, further comprising injecting the injectable material or printing theadditive build material with the material dispenser.
 13. The method ofclaim 11, further comprising injecting the injectable material andprinting the additive build material with the material dispenser. 14.The method of claim 13, further comprising switching the materialdispenser between the injectable material and the additive buildmaterial.
 15. The method of claim 10, further comprising locating afabric material within the mold cavity prior to injecting the injectablematerial into the mold cavity.
 16. A method of making a part with asystem for manufacturing a part in a mold, the method comprising:forming a mold with at least one mold portion having a mold cavity;depositing a first material within the mold cavity with a printhead;depositing a second material within the mold cavity with an injectionhead; and forming a part by cooperatively depositing the first materialby the printhead and the second material by the injection head.
 17. Themethod of claim 16, wherein depositing the second material comprisesdepositing a material different than the first material.
 18. The methodof claim 16, further comprising carrying the printhead and injectionhead with an arm.
 19. The method of claim 17, further comprisingselecting one of the printhead or the injection head for depositing ofthe corresponding first or second material into the mold cavity.